Sugar Process Automation Optimization

Sugar Process Automation
YU Technologies Pvt. Ltd.

Registered Office:
315, A1, 22, Manishanagar, Off Sahyadrinagar,
Sangli – 416 416, Maharashtra, India.
HO & Works:
B 8/5, MIDC, Miraj, 416 410, Distt: Sangli,
Maharashtra, India.
T: + 91 233 6451803 – 6; F: +91 233 2644042

E: info@yutech.in
W: www.yutech.in
Servicing the Sugar Industry

since 1978
Agenda
• Need for Automation

• Automation Approach
• Automation Examples
• Why choose YUTECH
• Case Study and Value Analysis
• Concluding Remarks
www.yutech.in; sale@yutech.in
Need for Automation
Energy savings by Save costs and money

improved throughput, by optimising the
gain in performance resources like Steam,
and efficiency Fuel, Power and water.
Achieve the minimum cost of

operations by streamlining
operations and increasing Throughput
The Purpose of Sugar Process Automation
• Sustained Increase in Productivity with Better

Quality
• Sustained Increase in Throughput thus Maximum
Equipment Utilization
• Save Energy and Steam thus Save Fuel
• Increase Work Efficiency thus Reduce Expenses
• Reduce Human Errors thus Reduce Downtime
• Reduce Production Costs thus Increase Profitability
Automation Effects on Process Parameters
• Maintain Optimum Juice Temperatures thus improve Efficiency

• Maintain Juice-Lime Mix Ratio & pH thus improve Juice Quality
• Maintain Juice Brix at the Evaporator Station thus improve Efficiency
• Maintain the Brix by proper Feeding to Pans, CVPs, Melters thus
improve Efficiency and reduce Cycle Time
• Ensure constant ratio of Magma and Molasses thus improve
Efficiency and reduce Cycle Time
• Maintain Flows, Levels, Temperatures and Pressures in different
vessels and Pipelines to Facilitate Consistant Operation thus improve
Efficiency and reduce Cycle Time
• Eliminate overflows, Reduce and Possibly Eliminate Stoppages due to
Human Errors thus reduce Cycle Time and Avoid Wastage thus
improve Profitability
• Early indications of Faults thus reduce Maintenance Costs
Automation Approach
Common Industrial Activities like Steam Generation or Process

Plants share common engineering parameters like Pressure,
Temperature, Flow and pH etc.
Sugar Process is completely different from normal Process Plant

activities because we deal with Variables and almost everything is
non standard.
Here a great stress is put on the abilities of a few technicians.

Therefore the Automation approach also differs greatly from other
common processes.
Automatic Sugar Process Control Systems:
• Juice Flow Stabilization and Control System

• pH and Lime Dozing Automation
• Clarifier Automation
• Rising and Falling Film Evaporator Automation
• Batch and Continuous Pans Automation
• Continuous Centrifugal Machine Automation
• Vertical Crystallizer Automation
• Sugar Melter Automation
• Molasses Conditioner Automation
• Superheated Wash Water System
• Pressure Reducing and De-Superheating Station Automation
• Condenser Automation
• Steam and Vapour Balancing System
Juice Flow Control an Stabilization:
Juice Flow Control an Stabilization:
• This Automation Loop is Basically a Function of

Mill Automation but sometimes also taken in the
Boiling House or Process Automation Side.
• Stable and Constant Juice Flow is very essential
for over Sugar Process to Function Smoothly
• Constant Juice Flow and Constant Heating Steam
Ensure (Both have to work in tandem with Good
Mill Automation) Efficient Boiling House or
Process Operation
Juice Flow Stabilization and Control Systems
Automatic Juice Flow Control System
Features:
• Level Transmitters for Sensing Juice Tank Level

• Maintain Constant Juice Flow to Process in a PID Loop with Respect to Tank
Level
• Tank Level also has Over-Riding Control on Cane Carrier Speeds as a
Feedback Control
• Juice Tank Level Sensing and Controls avoid Juice Overflow and Pump Dry
Run
• Juice Flow Control by Controlling Juice Pump VFD or Juice Bypass Valve
Juice Flow Control Screen Shot:
Juice Flow Control Actual Trend Screenshot:
Partial
Screen Shots
Juice Flow
Control
Systems of
Various
Projects
Challenges in Juice Liming Automation:
• If Juice Flow Variation is beyond a certain limit then Controlling

Lime Dose becomes almost impossible.
• Variation in Lime Baume makes it difficult to control as a ratio
controller (Lime Flow with respect to Juice Flow).
• Lime has settling properties and hence a normal Butterfly or
Globe Type Control Valve cannot be used.
• pH Sensing becomes difficult because of Scale deposition on the
Electrodes.
YUTECH Solutions:
• Accurate Juice Flow Control: Controlled Juice Flow from the Mills
to the Process.
• Quantitative and Qualitative Controls: Lime Flow Control with
respect to Juice Flow as a Coarse Control and Shock Lime pH
Sensing as a Fine Control to micro adjust the Juice pH.
• Specially Designed Lime Proportionator Unit with recycle outlet
which prevents choking due settled lime.
Advantages:
• Constant Juice pH
• Maintained Dorr pH
• Better Sugar Colour
YUTECH Solutions:
• pH Electrode Maintenance is a very Contentious but Important
Issue
• We suggest 2 Electrodes be maintained at a time one in sensing
position and other in a 0.1 Molar HCL Solution
• These Electrodes be swapped every 24 Hours
• pH Signal Standardization in pH Analyzer Standardization is a must
when Electrodes are Swapped or Changed
• These Electrodes be Cleaned by 0.1 Molar HCL Solution at the
beginning of every Shift
• This Practice will ensure Correct pH Readings
Pneumatic Lime Proportionator Unit:
• Specially designed Lime

Proportionator Unit to avoid Lime
Overflow, Choking and Lime Settling.
• Accurate Control on Milk of Lime

Flow.
• Better pH Control.
• Highly accurate and Error Free pH

Sensing.
• Trouble free and intelligent

operation.
Falling Film Evaporator Automation:
Sense Evaporator Body Level
Sense Juice Inlet Flow
Evaporator Level has to be

maintained for proper
Evaporation and Vapor
Generation
FFE Level is maintained by:

1. Controlling the Transfer Control Valve.
2. By increasing Recirculation.
3. If there is shortage of Inlet Juice due to some emergency then Hot
Water is added.
Inlet to FFE is from Evaporator 1st Body
FFE having a Partition
Evaporator Automation: FFE for 1st & 2nd Body and
Conventional Rising Film type 3rd & 4th Body
FFE has a Vertical Partition.

Inlet, Recirculation and Bypass Flows are Measured and Controlled
Evaporator Automation: FFE for 1st & 2nd Body and
Conventional Rising Film type 3rd & 4th Body
• Evaporator Level has to be maintained for

proper Evaporation and Vapor Generation.
• Inlet Flow to the FFE Body and Recirculation
have to be equal or in Preset Proportion.
• Logic is written to Maintain this Condition.
• Inlet, Recirculation and Bypass Flows are
measured and maintained as per requirement
by using Control Valves.
• Brix of Final Body Measured and Maintained
Evaporator Automations:
YUTECH-DALSONS 3 Way
Globe Valve
Screen Shot
Lokmangal Mouli Sugar Factory Screen Shot
Process Automations:
Field Instruments and Sensor Installations
Mag Flow Meter Installation

Jumbo Displays
Installation
Capillary &
Remote Seal
Diaphragm
Type LT
Installation Flanged LT Installation
Mass Flow Meter Installation
Brix Sensor Installation
• Evaporator Level Control

• Calendria Steam Pressure Control
• Evaporator Brix Control
• Condensate Contamination Monitoring and

Bypass using YUTECH 3 Way Valve
Evaporator Automations Results
Lokmangal Mauli Industries Ltd., Khed, Tal: Lohara, Dt: Osmanabad.
Evaporator Automation System included in Plant DCS: Quintuple

with first 3 Effects being Falling Film type
Achievements after Automation:

• Constant Outlet Brix
• Level is maintained hence Entrainment through Vapour is
eliminated
• Constant Evaporation results in Constant Vapour Generation
• Steam % Cane: 36 at Imbibition % Fibre 210
Continuous Vacuum Pan Automation:
• Auto Feeding of Molasses
• Auto Selection of Feed wrt Feed

Tank Levels
• Calendria Vapour Pressure

Control
• Individual Compartment Brix

Control
• Seed Flow Control with respect

to Molasses Flow
• Seed / Magma Flow Control with respect to Molasses / Liquor Flow
• Molasses and Seed Flowmeters sense Flow.
• Ratio Controller delivers exact Flow of Seed wrt Molasses Quantity by Controlling
Magma Pump VFD.
• Individual Compartment Brix Control by Auto Feeding of Molasses / Water into each
Compartment
• Brix Sensing of each Compartment by YUTECH Brix Analyzer for exact Brix
Measurement
• Control of Molasses Intake Valve wrt Brix Set Point and Sensed Value in a PID
Mode
• Addition of Water if Brix are higher than Set Point. This Logic is Built in the PLC /
DCS.
• Auto Selection of Feed wrt Feed Tank Levels (This Process is mostly Controlled by
Panman / Chemist)
• Level Transmitters are installed in each Feed Tank for the Pans
• Semi Automatic Feed Selection depending on Feeder Tank Levels with Manual
Bypass Option.
• Feed Selection is also done Automatically by the PLC itself if Factory Conditions
permit.
• Calendria Vapour Pressure Control
• Calendria Vapour Pressure is Measured by a Pressure Transmitter
• Vapour Control Valve Controls the Vapour intake and thus Pressure to maintain
Set Pressure in a PID Loop.
Field Instrument Installation and Cable Routing
Feed Tank Levels:
YUTECH Brix Analyzer
YUTECH Auto Cleaning Self Retractable Brix Sensor:
Cleaning Position - Sensor Shaft Retracted

Brix Analyzer with
Auto Purity Compensation
Product Code:
YU-ASD-BA-1005-CO-V02
For Continuous Operation
YU-ASD-BA-1005-BO-V02
For Batch Operation
Sensing Position – Sensor Shaft Pushed Out
Auto Retractable Self Cleaning Brix Sensor

Product Code: ASD-BS-SCW-1E-V02
YUTECH Brix Analyzer
YUTECH Auto Cleaning Self Retractable Brix Sensor:
Auto Retractable Self Cleaning Brix Sensor Product Code: ASD-BS-SCW-1E-V02

YUTECH Brix Sensor
Self Cleaning Auto Retractable Brix Sensor in Operation
Auto Retracting Self Cleaning Brix Sensor

installed on Continuous Vacuum Pan & Sugar
Melter in Picture below
Partial Screen Shot of Brix Reading

on SCADA
Auto Retracting Self

Cleaning Brix Sensor
installed on Batch Type
Vacuum Pan
Auto Retractable Self Cleaning Brix Sensor:
Product Code: ASD-BS-SCW-1E-V02
Brix Sensor Detects Signal variation with respect to change in Brix.
PT 100 RTD provided for Massecuite Temperature Sensing
Auto Retraction and Self Cleaning using Pneumatic Cylinder
Sensor is sheathed in PTFE Bar with Leak Proofing cum Cleaning Arrangement
Sensor Material: Stainless Steel
Sensor Washing Arrangement provided with ½” Solenoid Valve for Hot Water Spraying
Wash Water Spray Tube Material: Stainless Steel
Salient Features of YUTECH Brix Analyzer cum Transmitter with
On-line Calibration Software “YUTECH-AccessApp-BA”:
• Brix Sensor Detects Signal Deviation with respect to Solution Brix
• This Signal Deviation is then Processed in Analyzer to obtain Brix Reading
• YUTECH Brix Analyzer is equipped with Intelligent Auto Purity Compensation

Algorithm to derive the Brix accurately in Massecuites of varying Purity
• Very Easy Calibration and Online Brix Compensation Recalibration
• In-Built Automatic Temperature Compensation
• In-Built Self Cleaning and Washing of Sensor with pre-adjustable timing cycle
• 4-20 mA Output, Separate Modbus and Ethernet Communications
• On-line Calibration Software “YUTECH-AccessApp-BA” provides Remote Access

to Brix Analyzer for Calibration, Compensation and Trouble Shooting.
Brix Analyzer:
Batch and Continuous Vacuum Pans:
Brix Analyzers for Batch Type Vacuum Pan:

Brix Analyzers for Batch Type Vacuum Pans come with different Purity Compensation
Algorithm and as Batch Pans undergo periodic washings, there is Wash and Pan Drop
Compensation Algorithm, with Alarms for Pan Drop.
A, B and C Type:
Accuracy for Brix Sensing of Continuous and Batch Type Pans of B and C Type is 0.5 –
1.5 Brix, mostly working within +/-1 Brix.
Brix of A Type Massecuite can be Measured if material intake is restricted to Only One
Type of Material in that particular Pan. The purity of Syrup, AL, AH and Melt is
drastically different from each other, so sensing Brix in a Pan with an uncertain mix of
these materials is not possible. Reading Accuracy decreases in Pan Cutting Practice.
Brix Analyzers for Horizontal and Vertical Continuous Type Vacuum Pan:
Brix Analyzers for Continuous Type Vacuum come with Algorithm developed for
Sensing Brix in a Continuous Process, it is similar to other Continuous Processes like
Evaporators, Sugar Melters etc., with different calibrations.
Brix Analyzer: Applications in Sugar, Liquor,
Food & Beverages making Industries
Brix Calibration Varies for different applications.
Brix Measurement in following Sugar Process Applications:

• Juice Filtrate, Clarified Juice
• All Bodies of Rising or Falling Film Evaporators
• Batch and Continuous Vacuum Pans, Vertical Continuous Pans
• Molasses Conditioners, Sugar Melters
• Open Pans in Jaggery / Muscovado / Jaggery Powder / Khandsari Units
Brix Measurement in following Liquor, Food & Beverages Plant Applications:

• Molasses or Liquor Fermentation Vessels
• Maturation Tanks
• Thickening Vessels
Automation Screen Shots:
Batch Pan Automation:
• Brix Sensing of B, C Type Pans

• Pan Level Sensing by Remote Seal Type
Differential Pressure Transmitter.
• Variable Brix Set Point wrt Level.
• Crystallizer Level Sensing.
• Pug Mill Level Sensing.
• Vapor Inlet Control wrt Calendria
Pressure.
• Semi Automatic Pan Drop wrt Pan Brix
and Level in Crystalizer and Pug Mill
with Automatic Vacuum Break with
Manual Bypass Option.
• Automatic Steam Wash.
• Semi Automatic Feed Selection
depending on Feeder Tank Levels with
Manual Bypass Option.
Advantages and Challenges of
Batch Pan Automation:
Advantages
• Steam Savings
• Optimum Capacity Utilization through Continuous Operations
Challenges:
• B and C Type Batch Pans pose relatively lesser Challenges.
• Very Large variation in Purity of Material especially in A Type because Syrup,
Melt, A Heavy, A Light, Water all materials are used and sometimes in different
mixes.
• Panman’s mindset is used to age old technique of feeling the Massecuite by
hand and spreading it over a glass for visual inspection. This technique by
experience becomes fairly accurate backed with Lab readings. And it is difficult
to get them to rely on Automation.
YUTECH Solutions for Batch Pan Automation:
• Simple Operating Philosophy helps operators understand the

Automation and use it.
• Easy to understand and User Friendly Screens remove the
apprehensions of Panman about operating the Automation
System.
• Drawing Inference from the Panman’s experience and knowledge
we set the Brix Value wrt Sensor output to suit the Panman’s
interpretation with repeat accuracy.
• Proper Training to Factory Staff.
• Customization to suit factory requirements.
• In A Type avoid mixing materials and use different Pans for
different materials as far as possible.
Sugar Melter Automation:
• Maintain Constant Melt Brix.

• Maintain Constant Melt
Temperature.
• Save Steam.
• Save Water.
Molasses Conditioner Automation:
• Maintain Constant Molasses Brix.

• Maintain Constant Molasses
Temperature.
• Save Steam.
• Save Water.
• Ensure Constant Quality Feed to
Pans.
Molasses Conditioner and Sugar Melter
Automation:
Molasses Conditioner and
Sugar Melter Automation:
• Though these two Systems serve different Purposes, the Control

Philosophy for both is the Same.
• Advantages of Automating these equipments also remain similar
as listed below.
Advantages:
• Streamlined Process Applications due to Constant and Maintained
Outlet Brix and Temperature.
• Increased Efficiency.
The Principle and Purpose of
Condenser Automation
Principle:
• As Massecuite Level in Pan rises, Rate of Evaporation Reduces and
therefore Water Quantity required to create Vacuum also
reduces. Thus any Extra Water used after this point is a Wastage.
• Condenser Automation facilitates Required Vacuum Generation
using just Optimum Water and Power, thus reducing Wastage of
Excess Energy and Water.
• Temperature difference between Vapour and Vapour-Condensate
also affects Vacuum Generation and so does the Injection Water
Temperature which varies as per Ambient.
Purpose:
• Huge Power and Water Saving due to Controlled intake of Water.
• Facilitate Optimum Capacity Utilization.
Condenser Automation
Schematic, Actual SCADA Screenshot, HMI Picture
Condenser Automation Overall Schematic
Condenser Box and it’s Automation
• Multiple Entry Condenser Box.

• Separate Water Entry for Different Sets of Spray Nozzles and Spray
Jet and Water Quantity is Automatically Controlled to by
Respective Nozzle Set Valve wrt Vacuum.
• Number of Jets & Nozzles and Jet & Nozzle Diameters designed as
per Condenser Capacity.
• Complete Stainless Steel Construction, Strainer provided for each
Condenser Header.
• Water Pressure in the Common Injection Header maintained by
Controlling Injection Pump VFD.
• Jet Compartment Controlled by Separate Valve.
• Vapour and Tail Pipe Temperature Measured.
Pressure Reducing and De-Superheating Control
Station (PRDS)
• Maintain Preset Pressure

• Maintain Preset Temperature
whilst De-Super-heating
Continuous Centrifugal Machine Automation
Advantages:
• Constant Load on the Machine Basket results in Constant Machine Operation

at Optimum Current Consumption of the Drive Motor thus Saving Power.
• Constant Load on the Machine Basket results in Improved Purity as well as

Increased Throughput at the same time.
• Water and Steam saving is also a result of uniform flow of Massecuite.
• Higher Capacity Utilization of Continuous Centrifugal Machines and

Operational life improvement and Reduced Cost of Ownership.
• Eliminate Human Errors, Overflows and Stoppages thus acting as a STOP LOSS
• Power Saving of 20% for total Massecuite Curing. Very Attractive pay back.
Continuous Centrifugal Machine Automation
Concentric Split Diaphragm Control Valve for Continuous
Centrifugal Machine Automation:
Controlled Constant Sugar Massecuite Intake into the Continuous

Centrifugal Machine with respect to Drive Motor Load.
Sugar Massecuite is a very thick Slurry formed of Sugar Crystals and

Molasses and is very Sticky and Viscous Mass.
CSD or IRIS Type Valve’s Concentric Opening provides perfect solution

for dropping Sugar Massecuite into Centrifugal Machine. Spilling and
splattering is avoided, as Massecuite falls in the center of the Basket,
and so facilitating a perfect Machine Operation.
Concentric Split Diaphragm Pneumatic Control Valve
for Continuous Centrifugal Machine Automation:
Controlled Quantity of Massecuite drops

from the Concentric Opening (Split
opening from the Centre of the Valve)
Hence No Spilling or Splattering
Typical Concentric Opening Split

Diaphragm
Pneumatic Control Valve
Installation
Concentric Split Diaphragm Pneumatic Control Valve
for Continuous Centrifugal Machine Automation:
Continuous Centrifugal Machine’s Drive Motor Current Load is sensed.
The Current is maintained by taking exact amount of Feed by Controlling the CSD Valve
opening in a PID Loop.
YUTECH’s Precision CT Converters Sense the CT Load

and Convert the Signal to Isolated 4-20mA Signal
which is given to PID Controller which gives a very
finely tuned Output to the CSD Valve thus linearly
controlling the Massecuite Intake to Centrifuge.
Concentric Split Diaphragm Control Valve also called Iris Type
Valve: Product Code: CV-IR-1005-6-EP
Concentric Opening of Split Diaphragm Controlled by Electro-Pneumatic Positioner
Concentric Split Diaphragm Control Valve
Latest Installations with new Improved Design :
Latest Installations with new Improved Design:
Earlier Installations:
FACTS:
• Rugged Build Quality for Long Life.

• Heavy Duty Rugged Valve Construction absorbs all shocks and Vibrations.
• Valve Internals are of Heavy Gauge SS Construction and designed to
operate under heavy Massecuite loads without bending or deformation.
• Precise Flow Control due to Concentric Opening of Split Diaphragm
(similar to a camera aperture).
• Energy saving whilst Flow Control due to Free Passage through
Concentric Opening
• Low-noise due to Easy Passage
• Maintenance free
• Pneumatic Actuation with Electro-Pneumatic Positioner for smooth
Linear Control Action
• Operating Air Pressure 2 – 7 Kg/cm2
• Input 4-20mA from any external source
Specifications:
Valve Type : Concentric Split Diaphragm Type Central Opening Valve with
Camera Aperture like Action
Sizes : 2” (50mm) 3” (75mm) / 4” (100mm) / 6” ( 150mm) / 8”
(200mm) / 10” (250mm)
Body material : MS Fabricated / Other Material on Request
Valve Internals : SS 410 / 304 / 316L - On request
Bearings and wedges : SS
material
Sheathing : PTFE / PU
Actuation : Pneumatic Linear (2 -7 Kg/cm2 Air Pressure) / Electric -
Motorized / Hand - Wheel
Actuator Stroke : As per Valve Size
Positioner : Electro-Pneumatic / Electronic
Position Feedback : 4 – 20 mA / 0 – 5 VDC
(Optional)
Input (for Actuated Valves : 4 – 20 mA from any external source
only) Or
Push Buttons for Open and Close
Centralized Sugar Plant Automation Control
Rooms:
Centralized Sugar Plant Automation Control
Rooms:
Superior Quality Norms and Protection
for Automation Systems:
 UPS System
 Built-In Panel Isolation Transformer for Mains Power Supply
 RCD for Mains Power Supply
 MCB for Each Power Distribution Head
 EMI / RFI Filter for Mains Power Supply
 Switching Surge Arrestor for Controller Power Supply Head
 Isolation Barrier for all Analogue I/Os
 Potential Free Relay for all Digital I/Os
 Fuse TBs for all Digital I/Os
Advantages of Sugar Process Automation:
Operational Advantages:
 Stabilized Shock Lime and Final pH hence ensured Improvement

in Juice Clarity, Stabilized Dorr pH.
 Steam, Power and Water Savings thus Fuel Saving.
 Optimum Capacity Utilization.
 Increased Throughput.
 Maintained Grain Size thus better Sugar Quality.
 Better Sugar Colour.
 Higher Sugar Price.
 All this results in Substantial Economic Gains.
Why invest in YUTECH Products
• Experience of over 39 years with Expertise of a very

highly qualified Engineering Team.
• In-house Control System Design, Engineering,
Manufacturing and Software Development.
• In-house Sensor and Instruments Design and
Manufacture.
• Superior Technical Support.
• Excellent Quality Workmanship.
• Extensive Warranty Coverage
• Highly accurate calibration facilities with traceability
certifications.
• Feature Rich State of the Art Technology
developed and matured in the Sugar Environment.
YUTECH Technical Advantage:
• Highly Competent Engineering Team.

• In-house System Engineering.
• In-house Design and Development of Systems and
Controls.
• In-house Design and Development of Industrial
Electronic and Instrumentation Equipments.
• In-house Manufacturing of Industrial Electronic and
Instrumentation Equipments.
• In-house Software Development from Micro
Controller Programming to SCADA, PLC, DCS
Programming to Visual Basic etc.
Conclusion - Juice Flow and Liming Automatio:
Well Engineered and Good Automation Systems in

Juice Stabilization and Liming:
• Stable and Constant Juice Flow increases Juice

Heating Efficiency
• Reduces Overheating and Caramalization
• Improves Overall Boiling House and Plant
Efficiency
• Improves Sugar Colour and hence price
• Improves and Stabilises Dorr pH
Conclusion - Continuous Centrifugal Machines
Automation:
Well Engineered and Good Automation Systems in Continuous Centrifugal Machines:
• Reduce Cycle Time and Increase Throughput

• Maximize Machine Capacity Utilization
• Eliminate Stoppages due to Human Errors
• Eliminate Wastage through Basket Overflows
• Reduce Power, Steam and Water Consumption
• In some cases it is observed that One or Two Machines have been kept spare as
total load is taken care of by 4 Machines instead of 6
• Thus we can Conclude that Automation can get more Work Done from the Same
Mechanical Equipment and:
 Increase Profitability
 Reduce Cost of Ownership
 Increase Return on Investment
Conclusion Evaporation and Pan Automations:
Well Engineered and Good Automation Systems in Evaporators, Pans

and Melters:
• Improve Process Efficiency

• Reduce Cycle Time
• Increase Throughput
• Maximize Capacity Utilization
• Eliminate Stoppages due to Human Errors
• Eliminate Wastage through Overflows
• Reduce Power Consumption
• Reduce Steam Consumption
• Reduce Water Consumption
• Increase Profitability
Automations Result
ThyssenKrupp India Project Lokmangal Mauli Industries Ltd., Khed,

Tal: Lohara, Dt: Osmanabad
Evaporator Automation System included in Plant DCS: Quintuple

with first 3 Effects being Falling Film type
Achievements after Automation:

• Constant Outlet Brix
• Level is maintained hence Entrainment through Vapour is
eliminated
• Constant Evaporation results in Constant Vapour Generation
• Steam % Cane: 36 at Imbibition % Fibre 210
THANK YOU!
For your Time and Presence
SAVE FUEL
REDUCE CARBON FOOTPRINT
MAKE THE WORLD GREENER
AND YET, MAKE MONEY


Sugar Process Automation Optimization

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Sugar Process Automation

YU Technologies Pvt. Ltd.

T: + 91 233 6451803 – 6; F: +91 233 2644042

Servicing the Sugar Industry

• Need for Automation

Energy savings by Save costs and money

Achieve the minimum cost of

• Sustained Increase in Productivity with Better

• Maintain Optimum Juice Temperatures thus improve Efficiency

Common Industrial Activities like Steam Generation or Process

Sugar Process is completely different from normal Process Plant

Here a great stress is put on the abilities of a few technicians.

• Juice Flow Stabilization and Control System

• This Automation Loop is Basically a Function of

Automatic Juice Flow Control System

• Level Transmitters for Sensing Juice Tank Level

• If Juice Flow Variation is beyond a certain limit then Controlling

• Specially designed Lime

• Accurate Control on Milk of Lime

• Highly accurate and Error Free pH

• Trouble free and intelligent

Sense Evaporator Body Level

Sense Juice Inlet Flow

Evaporator Level has to be

FFE Level is maintained by:

FFE has a Vertical Partition.

• Evaporator Level has to be maintained for

Mag Flow Meter Installation

Mass Flow Meter Installation

Brix Sensor Installation

• Evaporator Level Control

• Condensate Contamination Monitoring and

Evaporator Automation System included in Plant DCS: Quintuple

Achievements after Automation:

• Auto Feeding of Molasses

• Auto Selection of Feed wrt Feed

• Calendria Vapour Pressure

• Individual Compartment Brix

• Seed Flow Control with respect

• Seed / Magma Flow Control with respect to Molasses / Liquor Flow

• Molasses and Seed Flowmeters sense Flow.

• Calendria Vapour Pressure Control

• Calendria Vapour Pressure is Measured by a Pressure Transmitter

Cleaning Position - Sensor Shaft Retracted

Sensing Position – Sensor Shaft Pushed Out

Auto Retractable Self Cleaning Brix Sensor

Auto Retractable Self Cleaning Brix Sensor Product Code: ASD-BS-SCW-1E-V02

Auto Retracting Self Cleaning Brix Sensor

Partial Screen Shot of Brix Reading

Auto Retracting Self

Brix Sensor Detects Signal variation with respect to change in Brix.

PT 100 RTD provided for Massecuite Temperature Sensing

Auto Retraction and Self Cleaning using Pneumatic Cylinder

Sensor Material: Stainless Steel

Wash Water Spray Tube Material: Stainless Steel

• Brix Sensor Detects Signal Deviation with respect to Solution Brix

• This Signal Deviation is then Processed in Analyzer to obtain Brix Reading

• YUTECH Brix Analyzer is equipped with Intelligent Auto Purity Compensation

• Very Easy Calibration and Online Brix Compensation Recalibration

• In-Built Automatic Temperature Compensation

• 4-20 mA Output, Separate Modbus and Ethernet Communications

• On-line Calibration Software “YUTECH-AccessApp-BA” provides Remote Access

Brix Analyzers for Batch Type Vacuum Pan: